RPTv4_6_3.dot 

10845 Report_R1 

10052009 01460010845 

REPORT ON ENGINEERING TESTING 

Performed for: 

DRESSER WAUKESHA 

CATALYST INLET AND OUTLET 

WAUKESHA, WI 

Client Reference No: 21918 Rev. 1 

CleanAir Project No: 10845 

Revision 1: October 5, 2009 

To the best of our knowledge, the data presented in this report are accurate, complete, 

error free, legible and representative of the actual emissions during the test program. 

Submitted by, Reviewed by, 

 

_________________________________ _________________________________ 

Scott Lehmann 

Midwest Engineering Group Leader 

slehmann@cleanair.com 

(800) 627-0033 ext. 4660 

Scott Brown 

Project Manager 

sbrown@cleanair.com 

(800) 627-0033 ext. 4544 

Dresser Waukesha

1101 West St. Paul Ave. 

Waukesha, WI 53188
DRESSER WAUKESHA Client Reference No: 21918 Rev. 1 

WAUKESHA, WI CleanAir Project No: 10845 

REVISION HISTORY ii 

Revision 1, Final 

REPORT ON ENGINEERING TESTING 

DRAFT REPORT REVISION HISTORY 

Revision: Date Pages Comments 

D0a 09/14/09 All Draft version of original document. 

D0b 09/22/09 Appendices A through E Finalize appendices. 

 

FINAL REPORT REVISION HISTORY 

Revision: Date Pages Comments 

0 09/24/09 All Final version of original document. 

1 10/05/09 Cover, ii 

1-3 

A-4 

Clarification to text. 

Correction in sampling time. 

 
DRESSER WAUKESHA Client Reference No: 21918 Rev. 1 

WAUKESHA, WI CleanAir Project No: 10845 

CONTENTS iii 

Revision 0, Final 

1 PROJECT OVERVIEW.....................................................................................................1-1

INTRODUCTION ..............................................................................................................1-1

Key Project Participants ...............................................................................................1-1

Test Program Parameters ............................................................................................1-1

TEST PROGRAM SYNOPSIS..........................................................................................1-2

Test Schedule...............................................................................................................1-2

Table 1-1: Schedule of Activities ............................................................................................1-2

Discussion of Test Program .........................................................................................1-2

2 RESULTS .........................................................................................................................2-1

Table 2-1: Laboratory Cell – Catalyst Inlet and Outlet – Conditions 1-3.................................2-1

Table 2-2: Laboratory Cell – Catalyst Inlet and Outlet – Conditions 4-6.................................2-1

Table 2-3: Laboratory Cell – Catalyst Inlet and Outlet – Conditions 7-9.................................2-2

Table 2-4: Laboratory Cell – Catalyst Inlet and Outlet – Conditions 10-12.............................2-2

Table 2-5: Laboratory Cell – Catalyst Inlet and Outlet – Conditions 13-15.............................2-3

Table 2-6: Laboratory Cell – Catalyst Inlet and Outlet – Conditions 16-18.............................2-3

Table 2-7: Laboratory Cell – Catalyst Inlet and Outlet – Conditions 19-21.............................2-4

Table 2-8: Laboratory Cell – Catalyst Inlet and Outlet – Conditions 22-24.............................2-4

Table 2-9: Laboratory Cell – Catalyst Inlet and Outlet – Conditions 25-27.............................2-5

Table 2-10: Laboratory Cell – Catalyst Inlet and Outlet – Conditions 28-30...........................2-5

Table 2-11: Laboratory Cell – Catalyst Inlet and Outlet – Conditions 31-33...........................2-6

Table 2-12: Laboratory Cell – Catalyst Inlet and Outlet – Conditions 34-36...........................2-6

Table 2-13: Laboratory Cell – Catalyst Inlet and Outlet – Conditions 37-39...........................2-7

Table 2-14: Laboratory Cell – Catalyst Inlet and Outlet – Conditions 40-42...........................2-7

Table 2-15: Laboratory Cell – Catalyst Inlet and Outlet – Conditions 43-45...........................2-8

Table 2-16: Laboratory Cell – Catalyst Inlet and Outlet – Condition 46..................................2-8

3 DESCRIPTION OF INSTALLATION................................................................................3-1

PROCESS DESCRIPTION...............................................................................................3-1

Figure 3-1: Catalyst Inlet Sampling Point ...............................................................................3-1

DESCRIPTION OF SAMPLING LOCATION ....................................................................3-2

Table 3-1: Sampling Points ....................................................................................................3-2

4 METHODOLOGY .............................................................................................................4-1

Table 4-1: Summary of Sampling Procedures........................................................................4-1

5 APPENDIX........................................................................................................................5-1

TEST METHOD SPECIFICATIONS ....................................................................................A

SAMPLE CALCULATIONS..................................................................................................B

PARAMETERS ....................................................................................................................C

FIELD DATA PRINTOUTS ..................................................................................................D

PLANT DATA.......................................................................................................................E
DRESSER WAUKESHA Client Reference No: 21918 Rev. 1 

WAUKESHA, WI CleanAir Project No: 10845 

PROJECT OVERVIEW 1-1 

Revision 0, Final 

INTRODUCTION 

Dresser Waukesha (Waukesha) contracted Clean Air Engineering (CleanAir) to 

perform a test program at its facility, located in Waukesha, Wisconsin, for engineering 

purposes. The testing was to assist Waukesha in its efforts to provide the United States 

Environmental Protection Agency (EPA) with high quality data, in regards to the 

emissions of hazardous air pollutants (HAPs) from an engine at various operating 

conditions, for consideration in EPA’s development of the National Emission Standards 

for Hazardous Air Pollutants (NESHAP) for these types of engines. 

Key Project Participants 

Individuals responsible for coordinating and conducting the test program were: 

 Dennis Spaulding – Dresser Waukesha 

 Mac Cochrane – CleanAir 

Test Program Parameters 

The testing performed at the inlet and outlet of the catalyst on a Waukesha model 

L7044GSI engine, located in Laboratory Cell #17, on August 5 through 8, 2009, 

included the following measurements: 

• formaldehyde 

• acetaldehyde 

• acrolein 

Additionally, Waukesha recorded the following measurements during the testing: 

• engine speed 

• horsepower 

• temperature 

• pressure 

• oxygen (O2) 

• nitrogen oxides (NOX) 

• carbon dioxide (CO2) 

• carbon monoxide (CO) 

• total hydrocarbons (THC) 

1 Project Overview 
DRESSER WAUKESHA Client Reference No: 21918 Rev. 1 

WAUKESHA, WI CleanAir Project No: 10845 

PROJECT OVERVIEW 1-2 

Revision 0, Final 

TEST PROGRAM SYNOPSIS 

Test Schedule 

The on-site schedule followed during the test program is outlined in Table 1-1. 

Table 1-1: 

Schedule of Activities 

Condition Date

Start 

Time

End 

Time Condition Date

Start 

Time

End 

Time

Condition 1 08/05/09 09:36 11:11 Condition 24 08/06/09 13:26 13:49

Condition 2 08/05/09 12:03 12:25 Condition 25 08/06/09 13:58 14:20

Condition 3 08/05/09 12:34 12:59 Condition 26 08/06/09 14:27 14:50

Condition 4 08/05/09 13:18 13:44 Condition 27 08/06/09 15:20 15:42

Condition 5 08/05/09 13:55 14:17 Condition 28 08/06/09 15:49 16:13

Condition 6 08/05/09 14:27 14:49 Condition 29 08/06/09 16:24 16:56

Condition 7 08/05/09 14:58 15:21 Condition 30 08/06/09 17:02 17:24

Condition 8 08/05/09 16:49 17:11 Condition 31 08/06/09 17:29 17:51

Condition 9 08/05/09 17:27 17:50 Condition 32 08/07/09 06:56 07:18

Condition 10 08/05/09 18:13 18:34 Condition 33 08/07/09 07:27 07:49

Condition 11 08/06/09 06:41 07:03 Condition 34 08/07/09 08:02 08:24

Condition 12 08/06/09 07:13 07:36 Condition 35 08/07/09 08:40 09:01

Condition 13 08/07/09 15:56 16:19 Condition 36 08/07/09 09:08 09:30

Condition 14 08/06/09 08:16 08:39 Condition 37 08/07/09 17:12 17:35

Condition 15 08/06/09 08:44 09:07 Condition 38 08/07/09 10:50 11:11

Condition 16 08/06/09 09:10 09:35 Condition 39 08/07/09 17:42 18:04

Condition 17 08/06/09 09:40 10:02 Condition 40 08/07/09 11:46 12:07

Condition 18 08/06/09 10:12 10:35 Condition 41 08/07/09 12:20 12:42

Condition 19 08/06/09 10:43 11:08 Condition 42 08/07/09 12:48 13:11

Condition 20 08/06/09 11:26 11:48 Condition 43 08/08/09 07:04 07:28

Condition 21 08/06/09 11:57 12:19 Condition 44 08/08/09 07:34 07:57

Condition 22 08/06/09 12:27 12:49 Condition 45 08/08/09 08:05 08:28

Condition 23 08/06/09 12:59 13:20 Condition 46 08/08/09 06:31 06:52

Discussion of Test Program 

Formaldehyde, acrolein and acetaldehyde concentrations were obtained by Extractive 

Fourier Transform Infrared (FTIR) Spectrometry, per EPA Method 320. The FTIR 

measurements were made on a hot-wet basis using an extractive system manufactured 

by MKS. The FTIR measurements followed the “Protocol for the Use of Extractive 

Fourier Transform Infrared (FTIR) Spectrometry for the Analysis of Gaseous 

Emissions from Stationary Sources”, Addendum to Test Method 320, 40 CFR 63 

Appendix A. In accordance with the method, exhaust gas was continuously extracted 

through heated Teflon sample lines and directly interfaced with the FTIR 

instrumentation. 
DRESSER WAUKESHA Client Reference No: 21918 Rev. 1 

WAUKESHA, WI CleanAir Project No: 10845 

PROJECT OVERVIEW 1-3 

Revision 1, Final 

TEST PROGRAM SYNOPSIS (CONTINUED) 

The sampling system utilized a Teflon line surrounded by a heated stainless steel probe 

for gas withdrawal at the stack location. The exit of the probe was followed by 

stainless steel tee, which allowed system calibrations and spiking. A heated Teflon 

sample line and a heated head pump delivered the exhaust gases to the FTIR system. 

Sampling line, filter, pump and sampling valve temperatures of greater than 300°F were 

maintained to reduce the potential of analyte loss in the sampling system. The gas 

stream remained heated all the way into the FTIR analyzer. 

The MKS Model 2030 FTIR analyzer consists of a medium-high resolution 

interferometer, heated fixed path absorption cell, a mercury cadmium telluride (MCT) 

detector (liquid nitrogen-cooled), electronics package and computer. The gas transport 

path inside the FTIR and the absorption cell was maintained at 150°C. 

MKS-Online Corporation produced the interferometer/electronics package. It is 

operated at a nominal spectral resolution of 0.5 wavenumber (0.5 cm-1). The heated 

absorption cell has a fixed pathlength of 5.5 meters. The mirrors and cell interior are 

gold-plated. 

Computer software was used to control the sampling system, acquire spectra and post 

process the spectra to provide quantification of the analyses in the sample. The 

software used was produced by MKS. The MKS library was utilized for this testing. 

Since IR analysis is inherently non-linear, it is imperative to use a multi-point 

calibration like those in the MKS library. While many of the EPA libraries reference 

spectra agree favorably with the MKS, formaldehyde is not one of them. The MKS 

formaldehyde calibration is in agreement with several respected laboratories, some of 

which utilize these libraries for certification of calibration gases. The acrolein data was 

reprocessed utilizing a different reference method, still within the MKS library, in order 

to reduce interferences. Utilizing this reference method, an MDL of 1.18ppm was 

obtained. 

The minimum detection limit for the FTIR data was determined by taking the standard 

deviation of the compounds of interest during Condition 1 and multiplied it by a factor 

of 3, which is suggested in ASTM D6348-03, Annex 2, MDC#2. 

Several of the plant data points collected for oxygen was slightly negative. These 

values were treated as zero for calculation purposes. 

A detailed presentation of the test conditions and results of analysis are shown in 

Tables 2-1 through 2-16 on pages 2-1 through 2-8. 

End of Section 1 – Project Overview 
DRESSER WAUKESHA Client Reference No: 21918 Rev. 1 

WAUKESHA, WI CleanAir Project No: 10845 

RESULTS 2-1 

Revision 0, Final 

Table 2-1: 

Laboratory Cell – Catalyst Inlet and Outlet – Conditions 1-3 

Condition

Test Date (2009)

Start 9:36 10:37 12:03 12:15 12:34 12:47

Stop 10:18 11:11 12:14 12:25 12:46 12:59

Engine Parameters

Load (hp) 1,681 1,681 1,173 1,173 976 976

Exhaust Parameters Pre-Cat Post- Cat Pre-Cat Post- Cat Pre-Cat Post- Cat

Carbon Dioxide (%) 11.34 11.90 11.41 11.96 11.52 11.91

Oxygen (%) 0.34 0.00 0.36 0.00 0.33 0.05

Moisture (%) 14.44 19.62 19.35 19.64 19.30 19.60

HAPs Emissions (ppmwv)

Acrolein <1.18 <1.18 <1.18 <1.18 <1.18 <1.18

Acetaldehyde <1.20 <1.20 <1.20 <1.20 <1.20 <1.20

Formaldehyde 3.76 <0.23 7.41 <0.23 6.89 <0.23

HAPs Emissions (g/hp-hr)

Acrolein <0.0004 <0.0005 <0.0103 <0.0103 <0.0091 <0.0091

Acetaldehyde <0.0004 <0.0005 <0.0106 <0.0105 <0.0093 <0.0093

Formaldehyde 0.0007 <0.0001 0.0349 <0.0021 0.0285 <0.0018

1

5-Aug

2

5-Aug

3

5-Aug

Table 2-2: 

Laboratory Cell – Catalyst Inlet and Outlet – Conditions 4-6 

Condition

Test Date (2009)

Start 13:29 13:44 13:55 14:07 14:27 14:39

Stop 0:00 0:00 14:05 14:17 14:38 14:49

Engine Parameters

Load (hp) 1,403 1,402 1,683 1,683 1,683 1,683

Exhaust Parameters Pre-Cat Post- Cat Pre-Cat Post- Cat Pre-Cat Post- Cat

Carbon Dioxide (%) 11.45 11.95 11.39 11.81 11.46 11.91

Oxygen (%) 0.33 0.00 0.28 0.00 0.38 0.07

Moisture (%) 19.36 19.64 19.43 19.62 19.36 19.56

HAPs Emissions (ppmwv)

Acrolein <1.18 <1.18 <1.18 <1.18 <1.18 <1.18

Acetaldehyde <1.20 <1.20 <1.20 <1.20 <1.20 <1.20

Formaldehyde 6.14 <0.23 5.05 <0.23 5.90 0.24

HAPs Emissions (g/hp-hr)

Acrolein <0.0053 <0.0053 <0.0059 <0.0059 <0.0072 <0.0071

Acetaldehyde <0.0054 <0.0054 <0.006 <0.0061 <0.0073 <0.0073

Formaldehyde 0.0148 <0.0011 0.0136 <0.0012 0.0192 0.0008

4

5-Aug

5

5-Aug

6

5-Aug

2 Results 
DRESSER WAUKESHA Client Reference No: 21918 Rev. 1 

WAUKESHA, WI CleanAir Project No: 10845 

RESULTS 2-2 

Revision 0, Final 

Table 2-3: 

Laboratory Cell – Catalyst Inlet and Outlet – Conditions 7-9 

Condition

Test Date (2009)

Start 14:58 15:10 16:49 17:02 17:27 17:39

Stop 15:09 15:21 17:00 17:11 17:37 17:50

Engine Parameters

Load (hp) 1,176 1,175 1,403 1,403 1,687 1,687

Exhaust Parameters Pre-Cat Post- Cat Pre-Cat Post- Cat Pre-Cat Post- Cat

Carbon Dioxide (%) 11.44 11.87 11.43 11.93 11.45 11.98

Oxygen (%) 0.41 0.11 0.29 0.00 0.32 0.00

Moisture (%) 19.30 19.54 19.45 19.58 19.39 19.65

HAPs Emissions (ppmwv)

Acrolein <1.18 <1.18 <1.18 <1.18 <1.18 <1.18

Acetaldehyde <1.20 <1.20 <1.20 <1.20 <1.20 <1.20

Formaldehyde 7.84 <0.23 6.05 <0.23 5.63 <0.23

HAPs Emissions (g/hp-hr)

Acrolein <0.0102 <0.0101 <0.006 <0.006 <0.0058 <0.0058

Acetaldehyde <0.0104 <0.0104 <0.0061 <0.0061 <0.006 <0.006

Formaldehyde 0.0363 <0.002 0.0165 <0.0012 0.0149 <0.0012

7

5-Aug

8

5-Aug

9

5-Aug

Table 2-4: 

Laboratory Cell – Catalyst Inlet and Outlet – Conditions 10-12 

Condition

Test Date (2009)

Start 18:13 18:24 6:41 6:53 7:13 7:25

Stop 18:23 18:34 6:52 7:03 7:24 7:36

Engine Parameters

Load (hp) 1,684 1,684 1,680 1,680 1,680 1,680

Exhaust Parameters Pre-Cat Post- Cat Pre-Cat Post- Cat Pre-Cat Post- Cat

Carbon Dioxide (%) 11.47 11.98 11.45 11.97 11.48 12.00

Oxygen (%) 0.32 0.00 0.33 0.00 0.32 0.00

Moisture (%) 19.38 19.68 19.37 20.45 19.40 19.85

HAPs Emissions (ppmwv)

Acrolein <1.18 <1.18 <1.18 <1.18 <1.18 <1.18

Acetaldehyde <1.20 <1.20 <1.20 <1.20 <1.20 <1.20

Formaldehyde 5.57 <0.23 5.60 <0.23 5.36 <0.23

HAPs Emissions (g/hp-hr)

Acrolein <0.0072 <0.0072 <0.0073 <0.0073 <0.0072 <0.0072

Acetaldehyde <0.0074 <0.0074 <0.0074 <0.0075 <0.0074 <0.0074

Formaldehyde 0.0184 <0.0014 0.0185 <0.0015 0.0177 <0.0014

10

5-Aug

11

6-Aug

12

6-Aug
DRESSER WAUKESHA Client Reference No: 21918 Rev. 1 

WAUKESHA, WI CleanAir Project No: 10845 

RESULTS 2-3 

Revision 0, Final 

Table 2-5: 

Laboratory Cell – Catalyst Inlet and Outlet – Conditions 13-15 

Condition

Test Date (2009)

Start 16:09 15:56 8:16 8:28 8:44 8:56

Stop 16:19 16:07 8:26 8:39 8:55 9:07

Engine Parameters

Load (hp) 1,683 1,683 1,681 1,680 1,680 1,680

Exhaust Parameters Pre-Cat Post- Cat Pre-Cat Post- Cat Pre-Cat Post- Cat

Carbon Dioxide (%) 11.48 11.99 11.50 12.02 11.48 11.99

Oxygen (%) 0.32 0.00 0.30 0.00 0.32 0.00

Moisture (%) 20.34 21.08 19.44 19.78 19.37 19.71

HAPs Emissions (ppmwv)

Acrolein <1.18 <1.18 <1.18 <1.18 <1.18 <1.18

Acetaldehyde <1.20 <1.20 <1.20 <1.20 <1.20 <1.20

Formaldehyde 5.04 0.63 4.97 <0.23 5.44 <0.23

HAPs Emissions (g/hp-hr)

Acrolein <0.0051 <0.0051 <0.0076 <0.0076 <0.0074 <0.0074

Acetaldehyde <0.0052 <0.0052 <0.0078 <0.0078 <0.0076 <0.0076

Formaldehyde 0.0117 0.0015 0.0173 <0.0015 0.0183 <0.0015

14

6-Aug

15

6-Aug

13

7-Aug

Table 2-6: 

Laboratory Cell – Catalyst Inlet and Outlet – Conditions 16-18 

Condition

Test Date (2009)

Start 9:10 9:24 9:40 9:52 10:12 10:24

Stop 9:22 9:35 9:50 10:02 10:23 10:35

Engine Parameters

Load (hp) 1,680 1,681 1,199 1,194 984 985

Exhaust Parameters Pre-Cat Post- Cat Pre-Cat Post- Cat Pre-Cat Post- Cat

Carbon Dioxide (%) 11.50 12.02 11.52 11.98 11.58 11.92

Oxygen (%) 0.32 0.00 0.32 0.00 0.37 0.13

Moisture (%) 19.35 19.68 19.34 19.66 19.41 19.56

HAPs Emissions (ppmwv)

Acrolein <1.18 <1.18 <1.18 <1.18 <1.18 <1.18

Acetaldehyde <1.20 <1.20 <1.20 <1.20 <1.20 <1.20

Formaldehyde 5.45 <0.23 6.49 <0.23 7.21 <0.23

HAPs Emissions (g/hp-hr)

Acrolein <0.0073 <0.0073 <0.01 <0.01 <0.0086 <0.0086

Acetaldehyde <0.0075 <0.0075 <0.0103 <0.0103 <0.0088 <0.0088

Formaldehyde 0.0181 <0.0015 0.0297 <0.002 0.0283 <0.0017

16

6-Aug

17

6-Aug

18

6-Aug
DRESSER WAUKESHA Client Reference No: 21918 Rev. 1 

WAUKESHA, WI CleanAir Project No: 10845 

RESULTS 2-4 

Revision 0, Final 

Table 2-7: 

Laboratory Cell – Catalyst Inlet and Outlet – Conditions 19-21 

Condition

Test Date (2009)

Start 10:43 10:56 11:26 11:38 11:57 12:09

Stop 10:55 11:08 11:37 11:48 12:08 12:19

Engine Parameters

Load (hp) 1,687 1,688 980 980 1,541 1,542

Exhaust Parameters Pre-Cat Post- Cat Pre-Cat Post- Cat Pre-Cat Post- Cat

Carbon Dioxide (%) 11.44 11.77 11.55 12.01 11.48 11.88

Oxygen (%) 0.23 0.00 0.30 0.00 0.27 0.00

Moisture (%) 19.31 19.67 19.30 19.64 19.36 19.70

HAPs Emissions (ppmwv)

Acrolein <1.18 <1.18 <1.18 <1.18 <1.18 <1.18

Acetaldehyde <1.20 <1.20 <1.20 <1.20 <1.20 <1.20

Formaldehyde 3.78 <0.23 6.84 <0.23 4.63 <0.23

HAPs Emissions (g/hp-hr)

Acrolein <0.0046 <0.0046 <0.0127 <0.0126 <0.0048 <0.0049

Acetaldehyde <0.0047 <0.0047 <0.013 <0.0129 <0.005 <0.005

Formaldehyde 0.0078 <0.0009 0.0395 <0.0025 0.0102 <0.001

19

6-Aug

20

6-Aug

21

6-Aug

Table 2-8: 

Laboratory Cell – Catalyst Inlet and Outlet – Conditions 22-24 

Condition

Test Date (2009)

Start 12:27 12:39 12:59 13:10 13:26 13:38

Stop 12:38 12:49 13:09 13:20 13:37 13:49

Engine Parameters

Load (hp) 1,401 1,402 1,176 1,175 1,682 1,681

Exhaust Parameters Pre-Cat Post- Cat Pre-Cat Post- Cat Pre-Cat Post- Cat

Carbon Dioxide (%) 11.47 11.89 11.52 11.94 11.53 11.98

Oxygen (%) 0.26 0.00 0.40 0.09 0.34 0.03

Moisture (%) 19.34 19.69 19.42 19.58 19.40 19.71

HAPs Emissions (ppmwv)

Acrolein <1.18 <1.18 <1.18 <1.18 <1.18 <1.18

Acetaldehyde <1.20 <1.20 <1.20 <1.20 <1.20 <1.20

Formaldehyde 4.78 <0.23 6.76 <0.23 4.94 <0.23

HAPs Emissions (g/hp-hr)

Acrolein <0.008 <0.008 <0.0085 <0.0084 <0.0056 <0.0056

Acetaldehyde <0.0082 <0.0082 <0.0087 <0.0086 <0.0058 <0.0058

Formaldehyde 0.0175 <0.0016 0.0261 <0.0017 0.0126 <0.0011

22

6-Aug

23

6-Aug

24

6-Aug
DRESSER WAUKESHA Client Reference No: 21918 Rev. 1 

WAUKESHA, WI CleanAir Project No: 10845 

RESULTS 2-5 

Revision 0, Final 

Table 2-9: 

Laboratory Cell – Catalyst Inlet and Outlet – Conditions 25-27 

Condition

Test Date (2009)

Start 13:58 14:10 14:27 14:39 15:20 15:31

Stop 14:08 14:20 14:38 14:50 15:29 15:42

Engine Parameters

Load (hp) 1,403 1,403 1,172 1,172 1,196 1,196

Exhaust Parameters Pre-Cat Post- Cat Pre-Cat Post- Cat Pre-Cat Post- Cat

Carbon Dioxide (%) 11.53 11.96 11.44 11.90 11.48 11.87

Oxygen (%) 0.35 0.03 0.30 0.00 0.38 0.12

Moisture (%) 19.41 19.62 19.26 19.68 19.41 19.45

HAPs Emissions (ppmwv)

Acrolein <1.18 <1.18 <1.18 <1.18 <1.18 <1.18

Acetaldehyde <1.20 <1.20 <1.20 <1.20 <1.20 <1.20

Formaldehyde 5.92 <0.23 5.93 <0.23 7.03 <0.23

HAPs Emissions (g/hp-hr)

Acrolein <0.009 <0.009 <0.0086 <0.0086 <0.0072 <0.0071

Acetaldehyde <0.0092 <0.0092 <0.0088 <0.0088 <0.0073 <0.0073

Formaldehyde 0.0243 <0.0018 0.0233 <0.0017 0.0229 <0.0014

25

6-Aug

26

6-Aug

27

6-Aug

Table 2-10: 

Laboratory Cell – Catalyst Inlet and Outlet – Conditions 28-30 

Condition

Test Date (2009)

Start 15:49 16:00 16:24 16:46 17:02 17:14

Stop 15:59 16:13 16:44 16:56 17:12 17:24

Engine Parameters

Load (hp) 974 975 974 974 1,397 1,397

Exhaust Parameters Pre-Cat Post- Cat Pre-Cat Post- Cat Pre-Cat Post- Cat

Carbon Dioxide (%) 11.55 11.87 11.56 11.89 11.48 11.94

Oxygen (%) 0.35 0.11 0.36 0.13 0.36 0.04

Moisture (%) 19.55 19.49 19.50 19.40 19.58 19.46

HAPs Emissions (ppmwv)

Acrolein <1.18 <1.18 <1.18 <1.18 <1.18 <1.18

Acetaldehyde <1.20 <1.20 <1.20 <1.20 <1.20 <1.20

Formaldehyde 6.52 <0.23 7.86 0.28 5.66 <0.23

HAPs Emissions (g/hp-hr)

Acrolein <0.0087 <0.0087 <0.0076 <0.0075 <0.0053 <0.0053

Acetaldehyde <0.0089 <0.0089 <0.0077 <0.0077 <0.0054 <0.0055

Formaldehyde 0.0259 <0.0017 0.0271 0.0010 0.0137 <0.0011

28

6-Aug

29

6-Aug

30

6-Aug
DRESSER WAUKESHA Client Reference No: 21918 Rev. 1 

WAUKESHA, WI CleanAir Project No: 10845 

RESULTS 2-6 

Revision 0, Final 

Table 2-11: 

Laboratory Cell – Catalyst Inlet and Outlet – Conditions 31-33 

Condition

Test Date (2009)

Start 17:29 17:40 6:56 7:08 7:27 7:39

Stop 17:38 17:51 7:07 7:18 7:37 7:49

Engine Parameters

Load (hp) 1,396 1,396 975 975 1,431 1,431

Exhaust Parameters Pre-Cat Post- Cat Pre-Cat Post- Cat Pre-Cat Post- Cat

Carbon Dioxide (%) 11.49 11.91 11.44 11.88 11.43 11.84

Oxygen (%) 0.27 0.00 0.29 0.00 0.40 0.11

Moisture (%) 19.30 19.59 17.32 19.50 19.30 20.53

HAPs Emissions (ppmwv)

Acrolein <1.18 <1.18 <1.18 <1.18 <1.18 <1.18

Acetaldehyde <1.20 <1.20 <1.20 <1.20 <1.20 <1.20

Formaldehyde 4.77 <0.23 5.25 <0.23 5.37 0.51

HAPs Emissions (g/hp-hr)

Acrolein <0.0072 <0.0072 <0.0075 <0.0076 <0.0053 <0.0054

Acetaldehyde <0.0074 <0.0074 <0.0077 <0.0077 <0.0055 <0.0055

Formaldehyde 0.0157 <0.0014 0.0179 <0.0015 0.0131 0.0013

31

6-Aug

32

7-Aug

33

7-Aug

Table 2-12: 

Laboratory Cell – Catalyst Inlet and Outlet – Conditions 34-36 

Condition

Test Date (2009)

Start 8:02 8:13 8:40 8:52 9:08 9:19

Stop 8:12 8:24 8:50 9:01 9:18 9:30

Engine Parameters

Load (hp) 1,197 1,198 978 978 1,075 1,076

Exhaust Parameters Pre-Cat Post- Cat Pre-Cat Post- Cat Pre-Cat Post- Cat

Carbon Dioxide (%) 11.44 11.83 11.48 11.91 11.45 11.90

Oxygen (%) 0.40 0.14 0.30 0.00 0.30 0.00

Moisture (%) 19.37 19.86 19.17 19.16 20.83 20.21

HAPs Emissions (ppmwv)

Acrolein <1.18 <1.18 <1.18 <1.18 <1.18 <1.18

Acetaldehyde <1.20 <1.20 <1.20 <1.20 <1.20 <1.20

Formaldehyde 7.12 0.67 6.37 0.51 5.42 0.44

HAPs Emissions (g/hp-hr)

Acrolein <0.009 <0.009 <0.0087 <0.0086 <0.0068 <0.0068

Acetaldehyde <0.0093 <0.0092 <0.0089 <0.0088 <0.007 <0.007

Formaldehyde 0.0294 0.0028 0.0252 0.0020 0.0169 0.0014

34

7-Aug

35

7-Aug

36

7-Aug
DRESSER WAUKESHA Client Reference No: 21918 Rev. 1 

WAUKESHA, WI CleanAir Project No: 10845 

RESULTS 2-7 

Revision 0, Final 

Table 2-13: 

Laboratory Cell – Catalyst Inlet and Outlet – Conditions 37-39 

Condition

Test Date (2009)

Start 17:12 17:25 10:50 11:02 17:42 17:53

Stop 17:23 17:35 11:00 11:11 17:51 18:04

Engine Parameters

Load (hp) 1,197 1,198 1,079 1,079 1,400 1,400

Exhaust Parameters Pre-Cat Post- Cat Pre-Cat Post- Cat Pre-Cat Post- Cat

Carbon Dioxide (%) 11.52 11.90 11.52 11.92 11.48 11.98

Oxygen (%) 0.38 0.11 0.40 0.13 0.35 0.00

Moisture (%) 19.93 20.19 18.85 18.02 20.08 20.14

HAPs Emissions (ppmwv)

Acrolein <1.18 <1.18 <1.18 <1.18 <1.18 <1.18

Acetaldehyde <1.20 <1.20 <1.20 <1.20 <1.20 <1.20

Formaldehyde 6.77 0.26 7.24 0.75 6.55 <0.23

HAPs Emissions (g/hp-hr)

Acrolein <0.0069 <0.0069 <0.0075 <0.0075 <0.0059 <0.0059

Acetaldehyde <0.0071 <0.0071 <0.0077 <0.0077 <0.0061 <0.0061

Formaldehyde 0.0213 0.0008 0.0248 0.0026 0.0177 <0.0012

37

7-Aug

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7-Aug

39

7-Aug

Table 2-14: 

Laboratory Cell – Catalyst Inlet and Outlet – Conditions 40-42 

Condition

Test Date (2009)

Start 11:46 11:57 12:20 12:32 12:48 13:01

Stop 11:56 12:07 12:30 12:42 12:59 13:11

Engine Parameters

Load (hp) 976 976 1,437 1,437 1,538 1,538

Exhaust Parameters Pre-Cat Post- Cat Pre-Cat Post- Cat Pre-Cat Post- Cat

Carbon Dioxide (%) 11.56 12.01 11.46 11.94 11.54 11.95

Oxygen (%) 0.28 0.00 0.31 0.00 0.40 0.13

Moisture (%) 19.39 19.03 19.29 18.86 18.87 18.62

HAPs Emissions (ppmwv)

Acrolein <1.18 <1.18 <1.18 <1.18 <1.18 <1.18

Acetaldehyde <1.20 <1.20 <1.20 <1.20 <1.20 <1.20

Formaldehyde 5.28 0.33 5.53 0.25 5.62 0.51

HAPs Emissions (g/hp-hr)

Acrolein <0.01 <0.01 <0.0053 <0.0053 <0.007 <0.0069

Acetaldehyde <0.0103 <0.0102 <0.0054 <0.0055 <0.0071 <0.0071

Formaldehyde 0.0241 0.0015 0.0134 0.0006 0.0179 0.0016

41

7-Aug

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7-Aug

40

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DRESSER WAUKESHA Client Reference No: 21918 Rev. 1 

WAUKESHA, WI CleanAir Project No: 10845 

RESULTS 2-8 

Revision 0, Final 

Table 2-15: 

Laboratory Cell – Catalyst Inlet and Outlet – Conditions 43-45 

Condition

Test Date (2009)

Start 7:04 7:16 7:34 7:46 8:05 8:17

Stop 7:14 7:28 7:44 7:57 8:15 8:28

Engine Parameters

Load (hp) 1,682 1,682 972 972 1,172 1,172

Exhaust Parameters Pre-Cat Post- Cat Pre-Cat Post- Cat Pre-Cat Post- Cat

Carbon Dioxide (%) 11.34 11.73 11.50 11.86 11.34 11.77

Oxygen (%) 0.27 0.00 0.37 0.13 0.30 0.00

Moisture (%) 20.22 20.47 20.27 20.50 20.27 20.59

HAPs Emissions (ppmwv)

Acrolein <1.18 <1.18 <1.18 <1.18 <1.18 <1.18

Acetaldehyde <1.20 <1.20 <1.20 <1.20 <1.20 <1.20

Formaldehyde 4.87 <0.23 7.60 <0.23 6.20 <0.23

HAPs Emissions (g/hp-hr)

Acrolein <0.005 <0.005 <0.0124 <0.0124 <0.0063 <0.0064

Acetaldehyde <0.0051 <0.0052 <0.0128 <0.0127 <0.0065 <0.0065

Formaldehyde 0.0111 <0.001 0.0432 <0.0025 0.0179 <0.0013

45

8-Aug

43

8-Aug

44

8-Aug

Table 2-16: 

Laboratory Cell – Catalyst Inlet and Outlet – Condition 46 

Condition

Test Date (2009)

Start 6:42 6:31

Stop 6:52 6:41

Engine Parameters

Load (hp) 1,080 1,080

Exhaust Parameters Pre-Cat Post- Cat

Carbon Dioxide (%) 11.34 11.83

Oxygen (%) 0.33 0.00

Moisture (%) 20.40 20.42

HAPs Emissions (ppmwv)

Acrolein <1.18 <1.18

Acetaldehyde <1.20 <1.20

Formaldehyde 7.11 <0.23

HAPs Emissions (g/hp-hr)

Acrolein <0.0092 <0.0091

Acetaldehyde <0.0094 <0.0094

Formaldehyde 0.0298 <0.0018

46

8-Aug

End of Section 2 – Results 
DRESSER WAUKESHA Client Reference No: 21918 Rev. 1 

WAUKESHA, WI CleanAir Project No: 10845 

DESCRIPTION OF INSTALLATION 3-1 

Revision 0, Final 

PROCESS DESCRIPTION 

Testing was performed in Laboratory Cell #17 on the exhaust gas stream of a 

Waukesha model L7044GSI engine. This engine is a spark-ignited, reciprocating, 

internal combustion engine that was burning utility pipeline, natural gas fuel. It 

operates on the four-stroke, Otto cycle that is typical of modern engines. The engine is 

of V-12 design with 9.375” bore x 8.5” stroke, displacement of 7040 cubic inches and 

8:1 nominal compression ratio. It is turbocharged and intercooled. 

All operation was at rich-burn, near stoichiometric (lambda nominally 0.995), 

combustion conditions for the proper chemical exhaust stream composition for use with 

a non-selective reduction catalyst (NSCR) (also known as a three-way catalyst). The 

catalyst used was a Maxim model 3WC 674-20. Emission measurements were made at 

both catalyst inlet (engine outlet) and catalyst outlet locations at every test condition. 

Figure 3-1: Catalyst Inlet Sampling Point 

3 Description of Installation 
DRESSER WAUKESHA Client Reference No: 21918 Rev. 1 

WAUKESHA, WI CleanAir Project No: 10845 

DESCRIPTION OF INSTALLATION 3-2 

Revision 0, Final 

DESCRIPTION OF SAMPLING LOCATION 

Table 3-1 outlines the sampling point configurations. 

Table 3-1: 

Sampling Points 

Source

Constituent

Catalyst Inlet and Outlet

Formaldehyde, 

Acrolein, 

Acetaldehyde

EPA M320 All 1 1 5 varied

Minutes per 

Point

Total 

Method Minutes

Run 

No.

Points per 

Ports Port

End of Section 3 – Description of Installation 
DRESSER WAUKESHA Client Reference No: 21918 Rev. 1 

WAUKESHA, WI CleanAir Project No: 10845 

METHODOLOGY 4-1 

Revision 0, Final 

CleanAir utilized a modified EPA Method 320. The following table summarizes the 

method and its respective source. 

Table 4-1: 

Summary of Sampling Procedures 

Title 40 CFR Part 63 Appendix A

Method 320 “Measurement of Vapor Phase Organic and Inorganic Emissions by Extractive Fourier 

Transform Infrared (FTIR) Spectroscopy” 

This method appears in detail in Title 40 of the Code of Federal Regulations (CFR) and 

on the World Wide Web at http://www.cleanair.com. 

Diagrams of the sampling apparatus and major specifications of the sampling, recovery 

and analytical procedures are summarized for each method in Appendix A. 

CleanAir followed specific quality assurance and quality control (QA/QC) procedures 

as outlined in the individual methods and in EPA “Quality Assurance Handbook for Air 

Pollution Measurement Systems: Volume III Stationary Source-Specific Methods”, 

EPA/600/R-94/038C. Additional QA/QC methods, as prescribed in CleanAir’s internal 

Quality Manual, were also followed. 

End of Section 4 – Methodology 

4 Methodology 
DRESSER WAUKESHA Client Reference No: 21918 Rev. 1 

WAUKESHA, WI CleanAir Project No: 10845 

APPENDIX 5-1 

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TEST METHOD SPECIFICATIONS ....................................................................................A

SAMPLE CALCULATIONS..................................................................................................B

PARAMETERS ....................................................................................................................C

FIELD DATA PRINTOUTS ..................................................................................................D

PLANT DATA.......................................................................................................................E

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